Insulated duct end system

ABSTRACT

The specification discloses a low-cost, simple, and efficient duct system for conveying heated and/or cooled air throughout a building. The system includes duct assemblies and transition components for interconnecting the duct assemblies. Each duct assembly includes an insulated duct having a rigid sleeve within at least one end. Each sleeve includes an abutment ring and orifices in the ring for permitting air to flow into the insulated layer to balloon the layer and improve its insulative effect. Each transition component includes a rigid external skeleton and a plurality of duct board panels fitted therein. After the sleeves are fitted within openings in the duct board panels, the tabs are deformed to retain the abutment rings in engagement with the panels.

This is a division of application Ser. No. 902,863, filed Sept. 2, 1986,now U.S. Pat. No. 4,735,235 issued April 5, 1988.

BACKGROUND OF THE INVENTION

This invention relates to insulated duct systems.

Insulated duct is widely employed in buildings for conveying heated airor cooled air for temperature control of interior environment. Typicallysuch systems are fabricated and installed on the job, in piecemealfashion, with tremendous waste of material being common. Skilledcraftsmen are necessary for interfitting sheet metal sections andflexible duct sections to form the duct network, but little effort isapplied toward optimum use of materials, such that a completed systemtypically is accompanied by piles of wasted scrap sheet metalcomponents, insulation, insulated flexible duct, and related materials.It is considered more economical to allow the highly paid craftsmen towaste material than to spend the time for determining optimum usagethereof. Moreover, it is difficult to try to optimize air flow throughthe various branches of the duct system. Thus, a small room supplied bythe system might receive tremendous air flow while a much larger roommight only receive minimal air flow. Flow restricting baffles are theninserted in register faces in an effort to alter such conditions,resulting in substantial air flow inefficiencies, audible whistlingeffects, and distracting "howling" sounds when air flow through largeducts is started and stopped.

Even with skilled craftsmen, the assembly techniques commonly usedusually result in leakage of the conveyed air. To overcome such leakage,which results in inefficiency, poor air flow, noise and condensation,ducting tape is liberally applied around all of the joints, somewhatcomparable to covering wounds with a generous supply of bandages.Ducting tape notoriously breaks loose in time, resulting in lostefficiency and higher energy usage.

In the particular problem area of the connection of an insulated duct toa duct board opening, one known technique is to place a clamp around thejoint and then wrap the entire area in ducting tape. But, as notedabove, taping is a poor temporary solution. Another technique is toplace a plastic or duct board ring around the end portion of the duct,inside of the exterior jacket of the insulated duct, and then insert theduct with its insulating jacket into the opening until the ring abutsthe duct board. But, air still leaks out between the duct board and thejacket to create problems.

In an attempt to overcome some of the above-noted prior art problems,the assignee of the present invention manufactured and sold a ductsystem including a plurality of duct assemblies interconnected usingtransition components. Each duct assembly included a flexible insulatedduct having rigid sleeves inserted at either end thereof. The duct wastaped to the sleeve using duct tape, which as noted above is aninefficient manner of interconnecting such components. The transitioncomponents each included a plurality of duct board panels taped togetherto form an enclosed polyhedron. These transition components proved to beof insufficient strength in installation and actual use. The taped ductboard panels also suffered the disadvantages noted above in conjunctionwith taping. To interconnect these elements, the duct sleeves wereinserted through openings cut in the duct board transition components;and bendable sleeve tabs were bent to retain the sleeves within thetransition components.

SUMMARY OF THE INVENTION

This invention provides a novel duct system having several uniquefeatures and advantages.

In a first aspect of the invention, the ends of the duct have a uniqueclosure and seal construction which not only closes off the duct againstleakage of air to the outside of the duct, but also creates a ballooningeffect beneath the jacket of the duct, to achieve a greater R-factorrating for the system. More specifically, each duct assembly includes aflexible duct and a pair of sleeves inserted at either end. The flexibleduct includes an insulation layer sandwiched between two air imperviouslayers. The rigid sleeves within either end of the duct define orificemeans permitting air to flow therethrough into the insulation layer forballooning thereof. Air leaking between the duct assembly and transitioncomponent is therefore "recaptured" in a manner enhancing the insulativevalue of the system.

In a second aspect of the invention, novel transition components areprovided for interconnecting the duct assemblies. Each transitioncomponent includes a rigid external framework and a plurality of ductboard panels or walls fitted therein. The transition components areextremely strong and can withstand the handling normally incurred priorto and during installation. In a preferred aspect, each frame element ofthe external skeleton is L-shaped to receive the edges of adjacent ductboard panels. Further preferably, an access opening is provided in oneof the duct board panels and is covered by a removable closure whichpermits an installer to reach into the transition component to connect aduct assembly thereto.

These and many other features, objects and advantages of the inventionwill be apparent upon studying the following specification inconjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective cutaway view of three components of the assemblyof this invention, namely a reinforced polymeric tube and a pair ofmetallic end sleeves;

FIG. 2 is a side elevational sectional view of the components in FIG. 1;

FIG. 3 is a perspective view of the components in FIGS. 1 and 2 plus apair of polymeric rings around the sleeves;

FIG. 4 is a side elevational partially sectional view of the componentsin FIG. 3;

FIG. 5 is a perspective view of the components in FIGS. 3 and 4 plus alayer of thermal insulation around and along the polymeric tube;

FIG. 6 is an elevational view of the components in FIG. 5;

FIG. 7 is a perspective view of the components in FIGS. 5 and 6 plus apair of peripheral clamps around the insulation layer and sleeves;

FIG. 8 is an elevational view of the components in FIG. 7;

FIG. 9 is a perspective view of the components in FIGS. 7 and 8 plus anannular collar at each end of the assembly;

FIG. 10 is an elevational view of the subassembly in FIG. 9;

FIG. 11 is an enlarged elevational partially sectioned view of theinvention, with the upper left end portion being comparable to thesubassembly in FIG. 2, the lower left end portion being comparable tothe subassembly in FIG. 4, the upper right end portion of FIG. 11 beingcomparable to the subassembly in FIGS. 7 and 8, and the lower right endportion being comparable to the subassembly in FIG. 10;

FIG. 12 is a perspective view of the right end of the assembly in FIG.11, showing some of the tabs of the metallic sleeve bent back over thepolymeric ring;

FIG. 13 is a side elevational sectional view of the structure in FIG.12;

FIG. 14 is a perspective view of an assembly of three of the ducts inFIGS. 12 and 13 connected to a novel transition component;

FIG. 15 is a breakaway perspective view showing the interconnection ofone of the ducts in FIG. 14 connected to one of the duct board panelsforming part of the transition component in FIG. 14;

FIG. 16 is a side elevational sectional view of the assembly in FIG. 15;

FIG. 17 an exploded perspective view of the transition component in FIG.14;

FIG. 18 is a top end view of the transition component in FIGS. 14 and17;

FIG. 19 is the view of FIG. 18 with a cover plate over the opening;

FIG. 20 is another view of FIGS. 18 and 19 with the cover plate rotatedinto locking position;

FIG. 21 is a top elevational view of a novel transition component madein accordance with the invention, but of a rectangular cross sectionalconfiguration rather than a triangular cross sectional configuration asin the transition component of FIGS. 14 and 17-20;

FIG. 22 is a view comparable to FIG. 1 but with a cover plate over theopening;

FIG. 23 is a view comparable to FIG. 22 but with the cover plate rotatedinto locked position;

FIG. 24 is a perspective view of a ceiling outlet for a system made inaccordance with the invention; and

FIG. 25 is a perspective view of an assembly of ducts and transitioncomponents.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings, the complete individual duct assembly(FIGS. 9 and 10) 10 is made up of a series of components the assembly ofwhich is shown sequentially in FIGS. 1-8. The central components includea conventional reinforced polymeric tube 12 reinforced by a helical wireor polymeric strand 14 along its length. Slid into the ends of thepolymeric tube is a pair of metallic sleeves 16, each of which includesan annular outwardly protruding rib 18 formed into its periphery. Theends of the polymeric tube abut against this rib, i.e., the axiallyinner wall of the rib, to locate the position of the sleeve relative tothe tube. The remaining portion of the sleeves extends beyond the endsof the tube and includes a solid annular portion 20 and an outer endportion severed into peripheral tabs 22.

A pair of rings 24, each L-shaped in cross sectional configuration, areslid over the outer ends of sleeves 16 until they abut against theaxially outer wall of ribs 18. Thus, the axially extending leg of thering 24 is positioned around the solid portion 20 of the sleeves 16,while the other leg protrudes radially outwardly, abutting against therib 18. By forming these rings of polymeric material, rather than metal,condensation on the ring surface is basically eliminated when theinsulated duct is used in a humid atmosphere, while conducting cold airtherethrough. The rings 24 may be riveted in place to the sleeves whilealso being retained by bending some of the tabs 22 over the leg 26 ofthe ring (FIGS. 12 and 13), or alternatively may simply be retained inplace by the bent tabs without rivets or the like. Although these ringsmay be placed on the subassembly prior to application of the insulation29, preferably the insulation is placed around the polymeric tube andthen the rings 24 slid over both ends of the subassembly, i.e., over thesleeves 16, to abut the ends of the insulation. This insulationcomprises a conventional layer of thermal insulation, e.g., a layer offiberglass 30 (FIG. 11) covered by a jacket 32 of aluminum foil or theequivalent. The ends of the insulation 30 and the tube 12 are clampedonto the inner ends 19 of sleeves 16 by a pair of peripheral outerclamps 34 comparable to hose clamps. This clamp or draw band closes upthe voids while accommodating any irregularities in the configuration.

An annular collar 38 extends around the ends of the insulation andjacket and includes a curled bead, U-shaped in cross section, whichencompasses the periphery of leg 28 of rings 24. (Lower right portion ofFIG. 11, as well as FIGS. 12-13 and 16). This annular collar extendsaxially inwardly on the duct from the end thereof to extend beyond clamp34. The overlapping peripheral ends of collar 38 are secured to eachother as by riveting, adhesive, or the equivalent, to maintain it insnug relationship forming a sealing ring to lock up the jacket whichalso extends around the peripheral edge of leg 28 (lower right portionof FIG. 11). The overlapping ends cause the collar 38 to act as a drawband to accommodate varying diameter elements and to fit over any roughspots in the elements.

Leg 28 of ring 24 includes orifices therethrough, e.g., slits, holes orotherwise, to allow a limited amount of air flow from the outer axialface of leg 28 through it and into the insulation between the airimpervious polymeric tube 12 and the overlying air impervious jacket 32for improved thermal insulation for reasons explained hereinafter.

Obviously the diameter and length of the flexible insulated ductassembly formed, and illustrated in FIGS. 9 and 10, will vary to suitthe usage involved. Typically it will be employed for conveying heatedair or cooled air for environmental control purposes. The novel assemblyhas been found particularly effective for rapid installation withresulting low thermal losses and minimal condensation characteristics,as well as negligible leakage, particularly when combined with the noveltransition components one embodiment of which is shown in FIGS. 14, 17and 18-20.

In FIG. 14, three of the novel duct assemblies 10 are shown combinedwith a transition component 50.

Transition component assembly 50 is formed in erector set type fashionby the use of novel elements which form a skeletal framework to combinewith and retain insulation board panels that comprise the walls.Specifically, the framework is formed of a plurality of elongatedmetallic components which are L-shaped in cross sectional configuration.Some of these elements, i.e., the parallel ones along the side edges,have end tabs which interfit with slots in the other elongated elements,i.e., the overlapping ones on the end edges. These metallic componentsare assembled with each other to secure the plurality of duct boardpanels..

More specifically, in the transition component 50, a pair of end ductboard panels 52 and 54, each triangular in configuration, are arrangedparallel to each other and interfit with a plurality, here three, ofside duct board panels 56 forming a three dimensional polygon. Each ofthese panels typically comprises compressed fiberglass insulation 56abonded to an external aluminum foil jacket 56. Unlike the insulationjacket around the duct, which is typically flexible, the duct panels, asis known in the trade, are basically stiff. These panels can be cut withdiagonal edges to interfit with each other at the appropriate angularrelationship depending upon whether the polygonal configuration istriangular in cross section as shown in the embodiment of FIGS. 14 and17, or some other polygonal shape such as rectangular (FIGS. 21-23),pentagonal, hexagonal, or other desired polygon.

The material of the duct board panels is readily severed as with a knifeso that suitable connecting orifices 56' can be cut into one or more ofthe panels. Here it is shown to be cut into all three panels 56 toaccommodate all three ducts 10 in FIG. 14. Preferably, the aluminumjacket of each panel is marked with different size potential orifices tobe cut therein (see the concentric numbered circles in FIG. 17) to allowthe installer to readily cut an opening of the desired diameter and toguide the cut for its desired circular configuration.

Panel 52 also may have cut thereinto, at the job site or initially, ahand insertion opening 52' for manually securing the insulated duct 10to the transition component by bending tabs in the manner explainedhereinafter.

After the plurality of duct board panels 52, 54 and 56 are positioned inedge abutment with each other to enclose the space therebetween, theskeletal framework is assembled along the edges of the structure. In theembodiment depicted, the three generally L-shaped elongated metallicelements 60 that extend along the abutting edges of the three panels 56that form the polygon are positioned so that each of the legs 62 and 64overlap one of the adjacent panels, while the connecting tabs 62' and64' on the ends thereof extend beyond the end panels 52 and 54. At eachend of the transition component is a plurality, here three in number, ofL-shaped elongated members 70. The legs 72 and 74 of these members areat a 90 degree angle to each other, while the legs of elements 60 are atan angle of 60 degrees to accommodate the angular relationship of thepanels. Elements 70 have elongated slot type orifices 70' severed intothe opposite end portions thereof. Thus, when elements 70 are placedover the adjacent edges of the end panels and side panels, tabs 62' and64' of the respective members 60 will fit through these slots. Then, bybending over the tabs, the assembly is secured as depicted in FIG. 14.

Assembly of the ends of the insulated ducts to the transition componentis readily made, in sharp contrast to the complicated assemblytechniques of the prior art devices. More specifically, by simplyproviding or cutting an orifice 52' into one of the end panels, e.g. 52(FIGS. 14 and 17), a person's hand can be inserted into the transitioncomponent to quickly bend over selected ones of the bendable tabs 22inserted into the chamber. The springy compressible characteristics ofthe duct board allows the tabs to be embedded therein while causing aspring-back force to snugly retain the components together. This occursafter the end of the duct is inserted through the side opening 56' ofpanels 56 until the radially outwardly extending annular leg 28 of ring24 abuts against the outer face of the panel. Then, by simply bendingover selected or remaining tabs 22 (FIGS. 15 and 16) into deformingengagement with the fiberglass layer 56a this secures the duct tightlyagainst the panel, with the curled bead of collar 38 engaging tightlyagainst and slightly compressing the outer face of the duct panel asdepicted in FIG. 16. The access opening 52' is then closed in a verysimple fashion.

More specifically, a cover plate 75 (FIGS. 14, 19 and 20) having apolygonal shape generally corresponding to the polygonal shape of thetransition component, and a size large enough to cover the opening 52'but small enough to fit within the outline of the skeletal framework andlie against the outer face of end panel 52 (FIG. 19), is positioned tocover the opening 52' and then rotated to cause the apices 75' thereofto slide between the skeletal components and adjacent panel 52 forretention of the cover plate in position. This can be readily done byslight deformation of the compressible end panel material. If accesslater need be made to the interior of the transition component, thecover plate simply is rotated back out of its locked position (FIG. 20)into its removable position (FIG. 19), and removed to uncover opening52' for access.

As mentioned previously, the particular cross sectional configuration ofthe transition component may be other than triangular, e.g., see therectangular configuration in FIGS. 21-23. In this instance, the endpanels would still be parallel to each other, but the peripheral panelswould be four in number and encompassed by a like plurality of skeletalframework elements. Moreover, if an end access opening is used for thistransition assembly 150, the opening 152' in the end panel 152 can becovered by a rectangular shaped cover plate 175 which is large enough tocover the opening 152' but small enough to fit within the skeletalframework of the assembly, against the outer face of panel 152, suchthat rotation of the cover plate (FIG. 23) will cause its apices 175' toslide between the skeletal elements and the end panel by slightdeformation of the end panel, thereby securing the cover plate inposition. Instead of this four sided polygon, the polygon may be of anydesired number of sides. Also, the number of connecting ducts can varyin number as desired.

In FIG. 24 is depicted a ceiling outlet structure for this novel system.More specifically, the polygonal component 80 has a pair of formedmetallic end walls 82 and 84 with flanges bent over the side panels 86.These side panels may be arranged in triangular configuration, with oneof them having an enlarged opening as shown to receive an adapter fromthe ceiling. A suitable opening can be formed in one wall for connectinga duct thereinto in the fashion described above relative to FIGS. 15 and16.

In FIG. 25 is depicted an assembled system of ducts 10, transitioncomponents 50, and ceiling outlets 80. The ducts and transitioncomponents are assembled to convey air from a central plenum 100 to theceiling outlets 80. Ducts of different diameter are selected fordifferent segments depending on the air volume handling requirements ofthe segments. As can be seen, the system can be easily configured to fita desired installation.

When the ducts are assembled to the transition components, air leakageis basically prevented. Moreover, no metallic surfaces exposed to thecold air are exposed to the ambient air to cause undesirablecondensation. Further, a controlled amount of air is allowed to passthrough the rings 16 into the porous insulation between the overlyingjacket and the underlying tube, to cause a ballooning effect on theflexible jacket. This air ballooning effect increases the R factorrating significantly. In other words, any so called leakage from thesystem actually serves an advantage rather than a disadvantage. Yet thejacket is locked up at the ends to form a tight assembly.

As a consequence of the invention, the duct and transition componentscan be preassembled at the manufacturer and simply supplied for readyinstallation at the job site rather than requiring complex assembly byskilled craftsmen. The final assembly can be quickly and easily made atthe site by semi-skilled labor, with very little or no waste.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows.
 1. A transition componentfor a duct system comprising:a plurality of rigid metallic elementsinterfitted into a skeletal framework, said framework defining a pair ofend planar portions in planes generally parallel to each other andperipheral planar portions in the form of a polygon between said endportions, said elements having connector means for interconnecting suchelements to form said skeletal framework; a pair of duct board panelswithin said end portions and a plurality of duct board panels withinsaid peripheral portions, said panels each having edges, a portion ofeach edge of each panel abutting an adjacent portion of an edge ofanother panel, panel holding means on each of said elements providingmeans for engaging said abutting panel edges for holding said panels inplace to enclose the space within said framework and panels, said panelsbeing individually capable of having an opening cut therein forinsertion of the end of a duct.
 2. The transition component in claim 1wherein said framework elements are L-shaped in cross section to receivesaid abutting edges of said duct board panels and providing said panelholding means to hold said panels in place.
 3. The transition componentin claim 2 wherein;one of said panels has a reach-in opening forinsertion of a hand to attach to said transition component a duct havingattachment means extending through an opening cut in at least one of theother of said panels; and a cover plate over said reach-in opening,rotatable between the said one panel and the adjacent framework elementsto be engaged therebetween and thereby retain said plate in closureposition.
 4. The transition component in claim 1 wherein:one of saidpanels has a reach-in opening for insertion of a hand to attach to saidtransition component a duct having attachment means extending through anopening cut in at least one of the other of said panels; and a coverplate over said reach-in opening.
 5. The transition component of claim 1in which some of said elements have said connector means extending fromthe ends thereof and received in openings in others of said elements forinterconnecting the elements to form said skeletal framework.
 6. Atransition component for a duct system comprising:at least two ducts; aplurality of rigid frame elements; means for interconnecting said frameelements to form an eternal skeleton defining a plurality of planarportions; and a plurality of resiliently compressible planar panels eachhaving edges, a portion of each edge of each panel abutting an adjacentportion of an edge of another panel, one of each panels being fittedwithin one of said skeleton planar portions, at least two of said panelshaving duct openings for receiving said ducts, said skeleton forming theexterior edges of said component and having means for engaging theabutting edges of said panels for holding the panels in place wherebyall of said frame elements and said panels together enclose saidtransition component to form a closed enclosure except for the ductsextending into and secured in said duct openings.
 7. The transitioncomponent in claim 6 wherein one of said panel defines an access openinglarge enough to receive a human hand for attaching a duct extendingthrough an opening in another panel, and further wherein said componentfurther comprises cover means for removably covering said accessopening.
 8. The transition component in claim 7 wherein said cover meanscomprises a plate overlying said one panel and rotatable between arelease position wherein said plate can be removed from said panel and alocked position wherein said plate is sandwiched between said one paneland a portion of said exterior skeleton.
 9. The transition component inclaim 6 wherein said interconnecting means comprise integral slots anddeformable tabs on said frame elements, said slots and tabs interfittingwith one another when said elements are arranged to define saidskeleton.
 10. The transition composition in claim 9 wherein each of saidframe elements is L-shaped in cross section to receive the abuttingedges of adjacent panels.
 11. The transition component in claim 10wherein said panels are beveled at their edges whereby a mitered jointis formed at the abutting panel edges received by the L-shaped frameelements to thereby improve the interfitting of said panels at saidframe elements.
 12. The transition component in claim 10 wherein saidpanels are fabricated of duct board.
 13. The transition component inclaim 6 wherein each of said frame elements is L-shaped in cross sectionto receive the abutting edges of adjacent panels.
 14. The transitioncomponent in claim 13 wherein one of said panels other than the twopanels receiving said duct defines an access opening, and wherein saidcomponent further comprises a closure plate overlying said one panel andshiftable between a release position wherein said plate can be removedfrom said one panel and a locked position wherein the edge of said plateis sandwiched between said one panel and at least one of said L-shapedframe members.